Connector with captive interface

ABSTRACT

Wedge type electrical connector assemblies adapted to electrically and mechanically connect conductors within transmission and/or distribution circuits is provided. The wedge type electrical connector assembly includes a frame, an interface and a wedge assembly. The interface is coupled to the frame so that it is movable relative to the frame. The interface can move and flex when installing conductors into the wedge type electrical connector assemblies.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present disclosure is based on and claims benefit from co-pendingU.S. Provisional Patent Application Ser. No. 62/977,656 filed on Feb.17, 2020 entitled “Connector with Captive Interface” and from co-pendingU.S. Provisional Application Ser. No. 63/115,529 filed on Nov. 18, 2020entitled “Connector with Captive Interface” the contents of each areincorporated herein in their entirety by reference.

BACKGROUND Field

The present disclosure relates generally to electrical connectors. Moreparticularly, the present disclosure relates to wedge type electricalconnectors adapted to electrically and mechanically interconnect mainconductors and tap conductors.

Description of the Related Art

Wedge type electrical connector assemblies are known in the art.Electrical connectors may be adapted to electrically and mechanicallyconnect conductors within a transmission or distribution circuit. Forexample, a typical electrical connector may be used to connect a mainconductor to a tap conductor. An electrical connector adapted to connecta main conductor or a tap conductor to another conductor may be referredto as a tap connector. Wedge type tap connectors typically include aC-shaped body having a curved top wall adapted to fit over a mainconductor. A bolt-operated wedge is carried by the bottom of theC-shaped body and may include an elongated recess in the top forsupporting the tap conductor. A conductor interface has a handle thereonwhich allows the interface to be placed within the C-shaped connectorbody between the conductors. A bolt positively moves the wedge both inand out of the C-shaped body so that the clamping action of theconnector can be tightened or loosened as desired.

However, the conductor interface is a separate component of such wedgetype electrical connector assemblies which requires additional steps andcare be taken in order to install the wedge type electrical connectorassemblies.

SUMMARY

The present disclosure provides exemplary embodiments of wedge typeelectrical connector assemblies adapted to electrically and mechanicallyconnect conductors within transmission and/or distribution circuits. Inan exemplary embodiment, the wedge type electrical connector assemblyincludes a frame, an interface and a wedge assembly. The frame has aconductor contact wall, a wedge support wall, a rear wall and a mountingmember. The rear wall is between the conductor contact wall and thewedge support wall. The conductor contact wall, wedge support wall andrear wall form a wedge receiving channel. The interface is movablycoupled to the frame by a connecting member so that the interface isflexible relative to the frame. The wedge assembly has a wedge and afastener. The wedge has a body shaped to fit within the wedge receivingchannel of the frame and a fastener holder extending from a side wall ofthe body. The fastener holder is aligned with the mounting member sothat the fastener can pass through the fastener holder into engagementwith the mounting member.

In another exemplary embodiment, the wedge type electrical powerconnector assembly includes a frame, an interface and a wedge assembly.The frame has a conductor contact wall, a wedge support wall, a rearwall and a mounting member. The rear wall is between the conductorcontact wall and the wedge support wall. The conductor contact wall,wedge support wall and rear wall form a wedge receiving channel. Theinterface is movably coupled to the frame by at least one connectingmember. The at least one connecting member includes a flexible memberhaving a base, a leg having one end attached to the base and a secondend positioned away from the base. The second end of the leg has aninterface coupling member attached thereto configured to attached to theinterface. The flexible member is preferably an elastomeric member. Thewedge assembly has a wedge and a fastener. The wedge has a body shapedto fit within the wedge receiving channel of the frame and a fastenerholder extending from the body. The fastener holder is aligned with themounting member so that the fastener can pass through the fastenerholder into engagement with the mounting member. The fastener is used tomove the wedge between an open position and a clamping position.

In another exemplary embodiment, the wedge type electrical powerconnector assembly includes a frame, an interface and a wedge assembly.The frame has a conductor contact wall, a wedge support wall, a rearwall and a mounting member. The rear wall is between the conductorcontact wall and the wedge support wall and includes at least oneopening. The conductor contact wall, wedge support wall and rear wallform a wedge receiving channel. The interface is positioned within thewedge receiving channel and coupled to the frame by at least oneflexible member. The at least one flexible member is preferably flexiblean elastomeric member that includes a base, a leg having one endattached to the base and a second end positioned away from the base. Thesecond end of the leg has an interface coupling member attached theretothat is configured to pass through the at least one opening in the rearwall. The wedge assembly has a wedge and a fastener. The wedge has awedge-shaped body that fits within the wedge receiving channel of theframe and a fastener holder extending from the body. The body of thewedge has a contact surface facing the conductor contact wall of theframe. The fastener holder is aligned with the mounting member so thatthe fastener can pass through the fastener holder into engagement withthe mounting member. The fastener moves the wedge between an openposition and a clamping position.

BRIEF DESCRIPTION OF THE DRAWINGS

A more complete appreciation of the present disclosure and many of theattendant advantages thereof will be readily obtained as the samebecomes better understood by reference to the following detaileddescription when considered in connection with the accompanyingdrawings, wherein:

FIG. 1 is a perspective view of an exemplary embodiment of a wedge typeelectrical cable connector assembly according to the present disclosure,illustrating a frame, a wedge assembly and a conductor interface of thecable connector assembly, with the cable connector assembly connected toa main conductor and a tap conductor;

FIG. 2 is an exploded perspective view of the wedge type electricalcable connector assembly of FIG. 1 without the tap conductor;

FIG. 3 is a rear side elevation view of the frame and conductorinterface of the wedge type electrical cable connector assembly of FIG.1, illustrating multiple slots in the frame and multiple flex connectingmembers mating the conductor interface to the frame;

FIG. 4 is an exploded perspective view of a first end of the frame andconductor interface of the wedge type electrical cable connectorassembly of FIG. 3, illustrating the multiple slots in the frame and themultiple flex connecting members positioned to mate the conductorinterface to the frame;

FIG. 5 is a front elevation view of the wedge type electrical cableconnector assembly similar to FIG. 1, illustrating the main and tapconductors inserted into the cable connector assembly, and the wedgeassembly pushing the tap conductor and conductor interface toward themain conductor;

FIG. 6 is a front elevation view of the wedge type electrical cableconnector assembly similar to FIG. 5, illustrating the main and tapconductors secured to the cable connector assembly and a shear fastenersheared from the wedge assembly after the main and tap conductors aresecured to the cable connector assembly;

FIG. 7 is a perspective view of another exemplary embodiment of theframe and conductor interface of the wedge type electrical cableconnector assembly according to the present disclosure, illustrating asingle slot in a frame of the cable connector assembly and a flexconnecting member extending through the slot in the frame and matingwith the conductor interface;

FIG. 8 is a perspective view of another exemplary embodiment of theframe and conductor interface of the wedge type electrical cableconnector assembly according to the present disclosure, illustrating aT-shaped slot in a frame of the cable connector assembly and a flexconnecting member extending through the slot in the frame and matingwith the conductor interface;

FIG. 9 is a first end perspective view of another exemplary embodimentof a wedge type electrical cable connector assembly according to thepresent disclosure, illustrating a frame, a wedge assembly and aconductor interface of the cable connector assembly, and illustratingthe main and tap conductors secured to the cable connector assembly;

FIG. 10 is a second end perspective view of the wedge type electricalcable connector assembly of FIG. 9;

FIG. 11 is a front elevation view of the frame of the wedge typeelectrical cable connector assembly of FIG. 9, illustrating multipleslots in the frame;

FIG. 12 is the first end elevation view of the frame and interface ofthe wedge type electrical cable connector assembly of FIG. 9,illustrating the conductor interface mated with the frame using the flexconnecting member;

FIG. 13 is an exploded perspective view of the conductor interface ofFIG. 12, illustrating a flex connecting member of FIG. 12 positioned tobe inserted within each mounting aperture in the conductor interface;

FIG. 14 is the second end elevation view of the wedge type electricalcable connector assembly of FIG. 10, illustrating a main conductorpositioned for insertion into the cable connector assembly;

FIG. 15 is the second end elevation view of the wedge type electricalcable connector assembly of FIG. 14, illustrating the main conductorbeing inserted into the cable connector assembly with the conductorinterface flexing to permit the main conductor to pass into contact witha conductor contact wall of the cable connector assembly;

FIG. 16 is the second end elevation view of the wedge type electricalcable connector assembly of FIG. 15, illustrating the main conductorcontacting the conductor contact wall and the conductor interface of thecable connector assembly;

FIG. 17 is a front elevation view of the frame and conductor interfaceof FIG. 16, illustrating a main conductor secured to the cable connectorassembly, and the wedge assembly positioned to receive a tap conductor;

FIG. 18 is a front elevation view of the frame and conductor interfaceof FIG. 17, illustrating the main conductor secured to the cableconnector assembly and the tap conductor secured to the cable connectorassembly;

FIG. 19 is a first end perspective view of another exemplary embodimentof a wedge type electrical cable connector assembly according to thepresent disclosure, illustrating a frame, a wedge assembly and aconductor interface of the cable connector assembly, a main conductorand tap conductor secured to the cable connector assembly;

FIG. 20 is a second end perspective view of the wedge type electricalcable connector assembly of FIG. 19, illustrating a frame, a wedgeassembly and a conductor interface of the cable connector assembly, withthe conductor interface flexing to permit a main conductor to be securedto the cable connector assembly;

FIG. 21 is an enlarged perspective view of a portion of the wedge typeelectrical cable connector assembly of FIG. 20, illustrating a retainingring used to secure a fastener to the wedge assembly;

FIG. 21a is an enlarged perspective view of a portion of the fastenerused to tighten the wedge of the wedge assembly to the frame,illustrating a triple-lead threaded portion of the fastener;

FIG. 21b is an enlarged cross-sectional view of a mounting member of theframe of FIG. 21, illustrating triple-lead threads in a threaded bore ofthe mounting member;

FIG. 22 is a front elevation view of the frame of the wedge typeelectrical cable connector assembly of FIG. 19, illustrating multipleslots in the frame;

FIG. 23 is an exploded perspective view of a second end of the frame ofthe wedge type electrical cable connector assembly of FIG. 20,illustrating a conductor interface and flex connecting memberspositioned for mating the conductor interface with the frame by a slidein operation;

FIG. 24 is the first end perspective view, in partial cut away, of theframe of the wedge type electrical cable connector assembly of FIG. 20,illustrating the conductor interface mated with the frame using the flexconnecting members;

FIG. 25 is an exploded rear perspective view of the conductor interfaceand flex connecting members of FIG. 24, illustrating a channel in theconductor interface for receiving an interface coupling member of theflex connecting members;

FIG. 26 is the second end elevation view of the wedge type electricalcable connector assembly of FIG. 19, illustrating a main conductorpositioned for insertion into the cable connector assembly;

FIG. 27 is the second end elevation view of the wedge type electricalcable connector assembly of FIG. 24, illustrating the main conductorbeing inserted into the cable connector assembly;

FIG. 28 is the second end elevation view of the wedge type electricalcable connector assembly of FIG. 25, illustrating the main conductorcontacting the conductor contact wall and the conductor interface of thecable connector assembly.

FIG. 29 is the front elevation view of the frame, conductor interfaceand flex connecting member of FIG. 19, illustrating a main conductorsecured to the cable connector assembly, and the wedge assemblypositioned to receive a tap conductor;

FIG. 30 is a front elevation view of the frame and conductor interfaceof FIG. 29, illustrating the main conductor secured to the cableconnector assembly and the tap conductor secured to the cable connectorassembly;

FIG. 31 is a second end perspective view of another exemplary embodimentof a wedge type electrical cable connector assembly according to thepresent disclosure, illustrating a frame, a wedge assembly and aconductor interface of the cable connector assembly, with the conductorinterface flexing to permit a main conductor to be secured to the cableconnector assembly;

FIG. 32 is an exploded side perspective view of the wedge assembly ofFIG. 31, illustrating a fastener operatively coupled to a wedge;

FIG. 33 is a front elevation view of the frame of the wedge typeelectrical cable connector assembly of FIG. 31, illustrating a singleslot in the frame;

FIG. 34 is an exploded perspective view of a second end of the frame ofthe wedge type electrical cable connector assembly of FIG. 31,illustrating the conductor interface and flex connecting memberpositioned for mating the conductor interface with the frame by a slidein operation;

FIG. 35 is the second end elevation view of the frame of the wedge typeelectrical cable connector assembly of FIG. 31 in partial cut away,illustrating the conductor interface mated with the frame using the flexconnecting member;

FIG. 36 is an exploded rear perspective view of the conductor interfaceand flex connecting member of FIG. 35, illustrating a channel in theconductor interface for receiving the flex connecting member;

FIG. 37 is the second end elevation view of the wedge type electricalcable connector assembly of FIG. 31, illustrating a main conductorpositioned for insertion into the cable connector assembly;

FIG. 38 is the second end elevation view of the wedge type electricalcable connector assembly of FIG. 37, illustrating the main conductorbeing inserted into the cable connector assembly;

FIG. 39 is the second end elevation view of the wedge type electricalcable connector assembly of FIG. 38, illustrating the main conductorcontacting the conductor contact wall and the conductor interface of thecable connector assembly.

FIG. 40 is the front elevation view of the frame, conductor interfaceand flex connecting members of FIG. 31, illustrating a main conductorsecured to the cable connector assembly and the wedge assemblypositioned to receive a tap conductor;

FIG. 41 is a front elevation view of the frame and conductor interfaceof FIG. 40, illustrating the main conductor secured to the cableconnector assembly and the tap conductor secured to the cable connectorassembly;

FIG. 42 is a rear perspective view of another exemplary embodiment of awedge type electrical cable connector assembly according to the presentdisclosure, illustrating a frame, a wedge assembly and a conductorinterface of the cable connector assembly;

FIG. 43 is a front perspective view of the frame of the wedge typeelectrical cable connector assembly of FIG. 42, illustrating twointerface stop members on the frame;

FIG. 44 is an exploded side perspective view of the wedge assembly ofFIG. 42, illustrating a fastener with an elongated unthreaded portionoperatively coupled to a wedge;

FIG. 45 is a front elevation view of the wedge type electrical cableconnector assembly of FIG. 42, illustrating threading of the fastener ina threaded bore of the mounting member of the frame;

FIG. 46 is a front elevation view of the wedge type electrical cableconnector assembly similar to FIG. 45, illustrating the unthreadedportion of the fastener extending from the threaded bore of the mountingmember;

FIG. 47 is a front elevation view of the wedge type electrical cableconnector assembly similar to FIG. 46, illustrating the unthreadedportion of the fastener extending further from the threaded bore of themounting member;

FIG. 48 is a rear perspective view of another exemplary embodiment of awedge type electrical cable connector assembly according to the presentdisclosure, illustrating a frame with ears, a wedge assembly and aconductor interface of the cable connector assembly;

FIG. 49 is an exploded front perspective view of the wedge typeelectrical cable connector assembly of FIG. 48;

FIG. 50 is a front perspective view of the frame of the wedge typeelectrical cable connector assembly of FIG. 48, illustrating two earsextending from a rear wall of the frame;

FIG. 51 is a front perspective view of another exemplary embodiment ofthe frame of the wedge type electrical cable connector assembly of FIG.48, illustrating two ears extending from a rear wall of the frame and aninterface stop member on each ear;

FIG. 52 is the front elevation view of the frame, conductor interfaceand flex connecting members of FIG. 48, illustrating a main conductorsecured to the cable connector assembly and the wedge assemblypositioned to receive a tap conductor; and

FIG. 53 is a front elevation view of the frame and conductor interfaceof FIG. 52, illustrating the main conductor secured to the cableconnector assembly and the tap conductor secured to the cable connectorassembly.

DETAILED DESCRIPTION

The present disclosure provides exemplary embodiments of improved wedgetype electrical cable connectors adapted to electrically andmechanically connect conductors within transmission or distributioncircuits. The wedge type electrical cable connectors contemplated by thepresent disclosure include, but are not limited to, wedge type tapconnectors. Wedge type tap connectors electrically and mechanicallyconnect a main conductor to a tap conductor, as shown in FIG. 1. Thewedge type electrical cable connectors according to the presentdisclosure flexibly mates a conductor interface with a frame of thewedge type electrical cable connector using one or more flex connectingmembers to facilitate easier installation of the wedge type electricalcable connector using extendable reach tools. For ease of description,the wedge type electrical cable connectors contemplated by the presentdisclosure may also be referred to herein as the “connectors” in theplural and the “connector” in the singular. The conductor interfacescontemplated by the present disclosure may also be referred to herein asthe “interfaces” in the plural and the “interface” in the singular. Theflex connecting members contemplated by the present disclosure may alsobe referred to herein as the “connecting members” in the plural and the“connecting member” in the singular. The main conductors referencedherein include, for example, transmission line conductors, and the tapconductors referenced herein include, for example, branch conductors.For general reference purposes, a main conductor supplies power fromeither a transmission circuit or a distribution circuit, and a tapconductor distributes power to a distribution circuit or a load.

Referring to FIGS. 1 and 4, an exemplary embodiment of a connector 10according to the present disclosure is shown electrically andmechanically connecting a main conductor 800 to a tap conductor 810. Theconnector 10 includes a wedge assembly 20, a frame 80, an interface 120and one or more connecting members 150, seen in FIGS. 4, 7 and 8. Thewedge assembly 20 is operatively coupled to or interconnected with theframe 80 so that the wedge assembly 20 can slide or glide along theframe to clamp a main conductor 800 to a tap conductor 810 so that themain conductor 800 and tap conductor 810 are electrically andmechanically connected, as will be described below. The wedge assembly20, frame 80 and interface 120 are made of an electrically conductivematerial that has sufficient rigidity to withstand the forces applied bythe wedge assembly 20 against the frame 80 when mechanically connectingthe main conductor 800 to a tap conductor 810. Non-limiting examples ofsuch electrically conductive and rigid materials include aluminum,aluminum alloys, stainless steel, galvanized steel, copper andcopper/brass alloys. The one or more connecting members 150 may also bemade of an electrically conductive material or a non-conductivematerial. Non-limiting examples of such electrically conductivematerials include aluminum, aluminum alloys, stainless steel, galvanizedsteel, copper and copper/brass alloys described above. Non-limitingexamples of such non-conductive materials include plastic materials andelastomeric materials. For example, the one or more connecting members150 may be made of Ethylene Propylene Diene Monomer (EPDM),Thermoplastic Elastomer (Rubber TPE) or Silicone.

Referring to FIGS. 1 and 2, in the exemplary embodiment shown, the wedgeassembly 20 includes a wedge 22 and a fastener 24. The wedge 22 includesa body 26 and a fastener holder 28. The body 26 has a front wall 30, arear wall 32, a top wall 34, a bottom wall 36 and side walls 38 and 40.The wedge body 26 is shaped to fit within the frame 80. At least aportion of the top wall 34 includes a contact surface 44, and at least aportion of the bottom wall 36 is substantially flat. The contact surface44 may be in the form of an elongated recess or groove as shown. Thecontact surface 44 is preferably configured to contact with a tapconductor 810 positioned in the frame 80. The fastener holder 28 extendsfrom the body 26 and includes an aperture 46 configured and dimensionedto receive the fastener 24 such that the fastener 24 can rotate relativeto the aperture 46. Preferably, the fastener holder 28 is positioned ator in proximity to the rear wall 32 of the body 26 and extends betweenthe side walls 38 and 40 so that the aperture 46 of the fastener holder28 is aligned with a bore 98 in the frame 80 when the wedge assembly 20is coupled to the frame 80. However, the present disclosure contemplatesthat the fastener holder 28 can be positioned at any location on thebody 26 so long as the aperture 46 of the fastener holder 28 aligns withthe bore 98 in the frame 80 when the wedge assembly 20 is coupled to theframe 80.

Referring to FIGS. 2, 5 and 6, the fastener 24 may be any fastenersuitable to releasably secure the wedge assembly 20 to the frame 80 asdescribed herein. In the exemplary embodiment shown, the fastener 24 isan elongated bolt having a head portion 50 followed by a threadedportion 52. The head portion 50 may be, for example, a breakaway headconfiguration where a portion of the head shears or breaks-away from thehead portion 50. In other embodiments, the head portion 50 may be aconventional hexagonal bolt head configuration. The head portion 50shown is a breakaway head configuration. Generally, the breakaway head50 includes a head nut 54, a shear stud 56 and a cap nut 58. It is notedthat the head nut 54 may include a washer 54 a or the washer may be aseparate member. The head nut 54 may be a hexagonal shaped nut that isused when removing the fastener 24 from the frame 80. The shear stud 56extends between the head nut 54 and the cap nut 58. The shear stud 56may be a circular structure that may have a tapered cross section, wherethe narrow portion of the taper is attached to the head nut 54 and thewide portion of the taper is attached to the cap nut 58. The shear stud56 is configured and dimensioned to shear at or above a threshold torqueso that the cap nut 58 shears or breaks away from the head portion 50.The diameters of the narrow portion and wide portion of the shear stud56 are determined by the desired predetermined torque at which the shearstud 56 is to shear. For example, if the predetermined torque is to bein the range of about 145 inch-lbs. to about 160 inch-lbs., the diameterfor the narrow portion of the shear stud 56 may be in the range fromabout 0.2 inches to about 0.3 inches, and the shear stud 56 tapersoutward from the narrow portion at an angle ranging from 5 degrees toabout 30 degrees. The cap nut 58 may be a hexagonal shaped nut that isused when clamping the main conductor 800 and the tap conductor 810 tothe connector 10 as described herein and that shears or breaks away whentightened sufficient to clamp the main conductor 800 and tap conductor810 to the connector 10. A more detailed description of a shear typehead portion is described in commonly owned U.S. Pat. No. 10,465,732which is incorporated herein in its entirety by reference.

Referring to FIGS. 2-4, in the exemplary embodiment shown, the frame 80is a C-shaped like body or member. The frame 80 has a conductor contactwall 82, a wedge support wall 84, and a rear wall 86 between theconductor contact wall 82 and the wedge support wall 84. Between theconductor contact wall 82, the wedge support wall 84 and the rear wall86 is a wedge receiving channel 88. The wedge receiving channel 88 at afirst end 90 of the frame 80 has a length “L1” and the wedge receivingchannel 88 at a second end 92 of the frame 80 has a length “L2.” In theembodiment shown, the length “L1” is less than the length “L2” such thatone or both of the conductor contact wall 82 and the wedge support wall84 are tapered relative to a longitudinal axis “A” of the frame 80. Inthe embodiment shown, the wedge support wall 84 is at an angle “α”relative to a longitudinal axis “A” of the frame 80. The angle “α” maybe in the range of about 5 degrees and about 25 degrees. In theembodiment shown, the conductor contact wall 82, the wedge support wall84, the rear wall 86 and the wedge receiving channel 88 form theC-shaped like body or member. The frame 80 may also include a stopmember 100, seen in FIG. 4, used to prevent longitudinal movement of theinterface 120 along axis “A” when mated with the frame 80.

The conductor contact wall 82 has an inner surface 82 a and an outersurface 82 b. The inner surface 82 a of the conductor contact wall 82 isshaped, e.g., arcuate shaped, to form a conductor groove that isconfigured and dimensioned to receive or fit at least partially around amain conductor 800. The wedge support wall 84 is configured anddimensioned to receive the fastener 24 and to provide a platform onwhich the bottom wall 36 of the wedge body 22 can slide along. In theexemplary embodiment shown, the wedge support wall 84 has an innersurface 84 a and an outer surface 84 b. The inner surface 84 a of thewedge support wall 84 is shaped, e.g., a U-shape like structure, to forma channel 94 that is configured and dimensioned to receive the fastener24. The wedge support wall 84 of the frame 80 includes a mounting memberor tab 96. The mounting member 96 is a substantially solid member havingan internally threaded bore 98 that passes through the mounting member.The threaded bore 98 is configured and dimensioned to receive thefastener 24. The mounting member 96 may be positioned at any point alongthe channel 94 of the wedge support wall 84. In the exemplary embodimentshown in FIG. 2, the mounting member 96 is positioned in close proximityto the second end 92 of the frame 80. The mounting member 96 may beintegrally or monolithically formed into the wedge support wall 84 orthe mounting member 96 may be secured to the wedge support wall 84 usingwelds, mechanical fasteners or adhesives. The wedge support wall 84 mayalso include an eyelet 102 used for connecting an extendable reach tool(not shown) to the connector 10.

The rear wall 86 of the frame 80 is a substantially flat wall having oneor more elongated opening 104, e.g., slots, through which a connectingmember 150 may pass to mate the interface 120 to the frame 80. In theexemplary embodiment of FIGS. 3 and 4 there are two elongated openings104. In the exemplary embodiment of FIG. 7 there is a single elongatedopening 104, and in the exemplary embodiment of FIG. 8 there is a singleT-shaped opening 104 having a cross-leg 104 a and a long leg 104 b.

Referring again to FIGS. 2 and 4, the interface 120 is an elongatedsolid or hollow body having a predefined length “L3” and a width “W2.”In the exemplary embodiment shown, the interface 120 has a length “L3”that is substantially the same as a width “W” of the frame 80. In theexemplary embodiment shown, the interface 120 is a rectangular bodyhaving first and second ends 120 a and 120 b, and first and second sidewalls 120 c and 120 d. A contact surface 122 is formed in an uppersurface of the interface 120, and a contact surface 124 is formed in alower surface of the interface. The contact surface 122 is configuredand dimensioned to receive or fit at least partially around a mainconductor 800. The contact surface 124 is configured and dimensioned toreceive or fit at least partially around a tap conductor 810. As shownin FIG. 1, when the wedge body 26 is positioned within the frame 80 andthe interface 120 is positioned between a main conductor 800 and a tapconductor 810, the contact surface 122 contacts a lower surface of themain conductor 800 and the contact surface 124 contacts an upper surfaceof the tap conductor 810. It is noted that the main conductor 800 andtap conductor 810, shown in FIG. 1, have substantially the same outerdiameter. Accordingly, the contact surface 122 and 124 formed in theupper and lower surfaces of the interface 120 have substantially thesame configuration. However, in some instances it may be desirable toconnect a tap conductor 810 having a smaller outer diameter to a mainconductor 800 having a larger outer diameter. In such situations, thecontact surface 122 would be configured to engage the larger outerdiameter main conductor 800 and the contact surface 124 would beconfigured to engage the smaller outer diameter tap conductor 810.

Either the first side wall 120 c or the second side wall 120 d of theinterface 120 includes one or more mounting elements 126, e.g.,apertures, configured and dimensioned to interact with the connectingmembers 150. In the exemplary embodiment of FIGS. 3 and 4 there are twoapertures 126 as mounting elements. In the exemplary embodiment of FIGS.7 and 8 there is a single aperture 126 as a mounting element. Theconnecting members 150 are provided to be mounted or attached to theinterface 120 and to mate the interface 120 to the frame 80 so that theinterface 120 can flex and move when installing the main conductor 800and the tap conductor 810 into the connector 10. In the exemplaryembodiment shown in FIGS. 1-7, each connecting member 150 is a set-screw152 that is passed through one of the elongated openings 104 in the rearwall 86 of the frame 80 into engagement with an aperture 126 in theinterface 120 to mate the interface 120 to the frame 80. The set screws152 are not fully tightened which allows the interface 120 to flex andmove axially and linearly relative to the frame 80 when installing themain conductor 800 and the tap conductor 810 into the connector 10. Inthe exemplary embodiment shown in FIG. 8, the connecting member 150 is aT-shaped set-screw 154 that can be inserted into the aperture 126 in theinterface 120 prior to installing the interface 120. The cross-leg ofthe T-shaped set screw is then passed through the cross-leg 104 a of theT-shaped opening 104 so that the set screw 154 can then slide along thelong-leg 104 b in the rear wall 86 of the frame 80 to mate the interface120 to the frame 80. The T-shaped set screw 154 is not fully tightenedwhich allows the interface 120 to flex and move axially and linearlyrelative to the frame 80 when installing the main conductor 800 and thetap conductor 810 into the connector 10.

Referring now to FIGS. 5 and 6, the electrical connector 10 can beinstalled in the following exemplary manner. The connector 10 is firstassembled where the interface 120 is mated to the frame 80 using theconnecting members 150 of FIGS. 3 and 4, and the wedge 22 is attached tothe frame 80 using the fastener 24 of the wedge assembly 20. The wedge22 is attached to the frame 80 so that wedge 22 is substantiallywithdrawn from a center of the frame 80, as shown in FIG. 5. At thispoint, the interface 120 is in close proximity to the wedge assembly 20.The connector 10 is then suspended from a main conductor 800 by placingthe inner surface 82 a, seen in FIG. 8, of the conductor contact wall 82onto the main conductor 800. When placing the inner surface 82 a of theconductor contact wall 82 onto the main conductor 800, the interface 120may need to move axially and/or linearly, e.g., flex, relative to theframe 80 so that the interface 120 is not obstructing the placement ofthe inner surface 82 a onto the main conductor 800. A tap conductor 810is then passed, e.g., slid, between the contact surface 124 in theinterface 120 and the contact surface 44 of the wedge body 26. As thetap conductor 810 is passed between the contact surface 124 in theinterface 120 and the contact surface 44, seen in FIG. 2, of the wedgebody 26, the interface 120 slides within the frame 80 toward theconductor contact wall 82. As noted above, the stop 100 on the frame 80,seen in FIG. 4, may be provided to prevent the interface 120 fromrotating as the interface 120 slides within the frame 80 toward theconductor contact wall 82. With the conductors 800 and 810 positionedwithin the connector 10, the fastener 24 is rotated, e.g., tightened, sothat wedge 22 moves toward and into the interior of the frame 80 causingthe contact surface 44 of the wedge body 26 to engage the bottom surfaceof the tap conductor 810. As the wedge 22 is further moved into theinterior of the frame 80, the wedge body 26 pushes the tap conductor 810into engagement with the contact surface 124 of the interface 120.Continued movement of the wedge 22 into the interior of the frame 80causes the interface 120 to move upwardly causing the contact surface122 of the interface 120 into contact with the main conductor 800.Continued tightening of the fastener 24 forces the main conductor 800against the inner surface 82 a of the conductor contact wall 82 of theframe 80. The fastener 24 is tightened until a stable, electricallyconductive path is established between the main conductor 800 and thetap conductor 810. In embodiments where the fastener 24 is a shearfastener, the cap nut 58 shears off when sufficient force has beenapplied by the wedge 22 against the tap conductor 810, the interface120, the main conductor 800 and frame 80, as described above. While theabove installation embodiment describes the connector 10 being suspendedfrom the main conductor 800 first and then the tap conductor 810 beinginstalled, the present disclosure also contemplates the tap conductor810 being installed first and then suspending the connector 10 and thetap conductor 810 from the main conductor 800.

Referring now to FIGS. 9-18, another exemplary embodiment of a connectoraccording to the present disclosure is shown and used to electricallyand mechanically connect a main conductor 800 to a tap conductor 810.The connector 200 includes a wedge assembly 220, a frame 280, aninterface 320 and one or more connecting members 350. The wedge assembly220 is operatively coupled to or interconnected with the frame 280 sothat the wedge assembly 220 can slide or glide along the frame 280 toclamp a main conductor 800 to a tap conductor 810 so that the mainconductor 800 and tap conductor 810 are electrically and mechanicallyconnected, as will be described below. The wedge assembly 220, frame 280and interface 320 are made of an electrically conductive material thathas sufficient rigidity to withstand the forces applied by the wedgeassembly 220 against the frame 280 when mechanically connecting the mainconductor 800 to a tap conductor 810. Non-limiting examples of suchelectrically conductive and rigid materials include aluminum, aluminumalloys, stainless steel, galvanized steel, copper and copper/brassalloys. The one or more connecting members 350 may also be made of anelectrically conductive material or a non-conductive material.Non-limiting examples of such electrically conductive materials includealuminum, aluminum alloys, stainless steel, galvanized steel, copper andcopper/brass alloys described above. Non-limiting examples of suchnon-conductive materials include plastic materials and elastomericmaterials. For example, the one or more connecting members 350 may bemade of Ethylene Propylene Diene Monomer (EPDM), Thermoplastic Elastomer(Rubber TPE) or Silicone.

Referring to FIGS. 9, 10 and FIGS. 14-16, in the exemplary embodimentshown, the wedge assembly 220 includes a wedge 222 and a fastener 224.The wedge 222 includes a body 226 and a fastener holder 228. The body226 has a front wall 230, a rear wall 232, a top wall 234, a bottom wall236 and side walls 238 and 240. The wedge body 226 is shaped to fitwithin the frame 280. At least a portion of the top wall 234 includes acontact surface 244, and at least a portion 236 a of the bottom wall 236is flat and a portion 236 b of the bottom wall 236 extends from the flatportion 236 a forming a rail. In the embodiment shown, the bottom wall236 includes two flat portions 236 a provided to glide along the uppersurfaces 284 a and 284 b of the frame 280, and the rail portion 236 b ofthe bottom wall 236 is received within a channel 294, seen in FIG. 12,of the frame 280. The contact surface 244 may be an arcuate surface inthe form of an elongated recess or groove as shown. The contact surface244 is preferably configured to contact a tap conductor 810 positionedin the frame 280. The fastener holder 228 extends from the body 226 andincludes an aperture 246 configured and dimensioned to receive thefastener 224 such that the fastener 224 can rotate relative to theaperture 246. Preferably, the fastener holder 228 is positioned at or inproximity to the rear wall 232 of the body 226 and extends away from theside wall 240 so that the aperture 246 of the fastener holder 228 isaligned with a bore 298 in the frame 280, seen in FIG. 12, when thewedge assembly 220 is coupled to the frame 280. However, the presentdisclosure contemplates that the fastener holder 228 can be positionedat any location on the body 226 so long as the aperture 246 of thefastener holder 228 aligns with the bore 298 in the frame 280 when thewedge assembly 220 is coupled to the frame 280.

Continuing to refer to FIG. 10, the fastener 224 may be any fastenersuitable to releasably secure the wedge assembly 220 to the frame 280 asdescribed herein. In the exemplary embodiment shown, the fastener 224 isthe same as the fastener 24 described above such that like numerals willbe used. Generally, the fastener 224 is an elongated bolt having a headportion 50 followed by a threaded portion 52. The head portion 50 maybe, for example, a breakaway head configuration where a portion of thehead shears or breaks-away from the head portion 50. In otherembodiments, the head portion 50 may be a conventional hexagonal bolthead configuration. The head portion 50 shown is a breakaway headconfiguration described above. A more detailed description of a sheartype head portion is described in commonly owned U.S. Pat. No.10,465,732 which is incorporated herein in its entirety by reference.

Referring now to FIGS. 9-12, in the exemplary embodiment shown, theframe 280 is a C-shaped like body or member. The frame 280 has aconductor contact wall 282, a wedge support wall 284, and a rear wall286 between the conductor contact wall 282 and the wedge support wall284. Between the conductor contact wall 282, the wedge support wall 284and the rear wall 286 is a wedge receiving channel 288. The wedgereceiving channel 288 at a first end 290 of the frame 280 has a length“L1” and the wedge receiving channel 288 at a second end 292 of theframe 280 has a length “L2.” In the embodiment shown, the length “L1” isless than the length “L2” such that one or both of the conductor contactwall 282 and the wedge support wall 284 are tapered relative to alongitudinal axis “A” of the frame 280. In the embodiment shown, thewedge support wall 284 is at an angle “α” relative to a longitudinalaxis “A” of the frame 280. The angle “α” may be in the range of about 5degrees to about 25 degrees. In the embodiment shown, the conductorcontact wall 282, the wedge support wall 284, the rear wall 286 and thewedge receiving channel 288 form the C-shaped like body or member. Theframe 280 may also include a stop member 300, seen in FIG. 11, used toprevent longitudinal movement of the interface 320 along axis “A” whenmated with the frame 280. The stop member 300 may also limit andpossibly prevent rotation of the interface 320 when tightening thefastener 224 to secure the main conductor 800 and the tap conductor 810to the frame 280.

The conductor contact wall 282 has an inner surface 282 a, an outersurface 282 b and a lead-in 283. The inner surface 282 a of theconductor contact wall 282 is shaped, e.g., arcuate shaped, to form aconductor groove that is configured and dimensioned to receive or fit atleast partially around a main conductor 800. The lead-ins 283 and 322help to guide the main conductor 800 toward and into the conductorcontact wall 282 as described above. The wedge support wall 284 includesone or more upper surfaces 284 a and 284 b and the channel 294. In theembodiment shown, the wedge support wall 284 includes two upper surfaces284 a and 284 b. The upper surfaces 284 a and 284 b are configured anddimensioned to interact with the flat portions 236 a of the bottom wall236 of the wedge body 226 so that the wedge body 226 can glide along theupper surfaces 284 a and 284 b when the wedge body 226 moves between theloading position and the clamping position. It is noted that in theloading position a center of the wedge body 226 is away from a center ofthe frame 280 sufficient so that the main conductor 800 and the tapconductor 810 can be installed in the frame, as shown in FIG. 17. In theclamping position a center of the wedge body 226 is close to a center ofthe frame 280 sufficient so that the main conductor 800 and the tapconductor 810 are electrically and mechanically connected, as shown inFIG. 18.

In the exemplary embodiment shown, the wedge support wall 284 also hasan inner surface 284 c and an outer surface 284 d, seen in FIG. 12. Theinner surface 284 c of the wedge support wall 284 is shaped, e.g., aU-shaped like structure, to form the channel 294 that is configured anddimensioned to receive the fastener 224. The wedge support wall 284 ofthe frame 280 includes a mounting member or tab 296 extending from thewedge support wall 284 and/or the rear wall 286, as shown. The mountingmember 296 is a substantially solid member having an internally threadedbore 298 that passes through the mounting member 296. The threaded bore298 is configured and dimensioned to receive the fastener 224. Themounting member 296 may be positioned at any point along the channel 294of the wedge support wall 284. In the exemplary embodiment shown in FIG.12, the mounting member 296 is positioned in close proximity to thesecond end 292 of the frame 280. The mounting member 296 may beintegrally or monolithically formed into the wedge support wall 284and/or the rear wall 286, or the mounting member 296 may be secured tothe wedge support wall 284 and/or the rear wall 286 using welds,mechanical fasteners or adhesives. The wedge support wall 284 may alsoinclude an eyelet 302 used for connecting an extendable reach tool (notshown) to the connector 200.

The rear wall 286 of the frame is a substantially flat wall having oneor more openings 304, e.g., slots, through which the connecting member350 may pass to mate the interface 320 to the frame 280. In theexemplary embodiment of FIG. 11 there are two openings 304. But, asdescribed above, there may be a single opening, or other opening, suchas the T-shaped opening described above.

An exemplary embodiment of the interface 320 is shown in FIGS. 12 and13. The interface 320 is an elongated solid or hollow body having apredefined length “L3” and a width “W2.” In the exemplary embodimentshown, the interface 120 has a length “L3” that is substantially thesame as a width “W” of the frame 280. In the exemplary embodiment shown,the interface 320 is a rectangular body having first and second ends 320a and 320 b, and first and second side walls 320 c and 320 d. A lead-in322 may extend from either the first side wall 320 c or the second sidewall 320 d. A contact surface 324 is formed in an upper surface of theinterface 320, and a contact surface 326 is formed in a lower surface ofthe interface 320. The contact surface 324 is configured and dimensionedto receive or fit at least partially around a main conductor 800. Thecontact surface 326 is configured and dimensioned to receive or fit atleast partially around a tap conductor 810. As shown in FIGS. 13 and 17,when the wedge assembly 220 is coupled to the frame 280 and theinterface 320 is positioned between a main conductor 800 and a tapconductor 810, the contact surface 324 contacts a lower surface of themain conductor 800 and the contact surface 326 contacts an upper surfaceof the tap conductor 810. It is noted that the main conductor 800 andtap conductor 810, shown in FIG. 17, have substantially the same outerdiameter. Accordingly, the contact surface 324 and 326 formed in theupper and lower surfaces of the interface 320 have substantially thesame configuration. However, in some instances it may be desirable toconnect a tap conductor having a smaller outer diameter to a mainconductor having a larger outer diameter. In such situations, thecontact surface 324 would be configured to engage the larger outerdiameter main conductor 800 and the contact surface 326 would beconfigured to engage the smaller outer diameter tap conductor 810.

Either the first side wall 320 c or the second side wall 320 d of theinterface 320 includes one or more mounting elements 328, e.g.,apertures, configured and dimensioned to interact with the connectingmembers 350. In the exemplary embodiment of FIG. 13 there are twoapertures 328 as the mounting elements. However, as described abovethere may be instances where a single aperture 328 as a mounting elementmay be desired. As shown in FIGS. 12 and 13, the connecting members 350are provided to be mounted or attached to the interface 320 and to matethe interface 320 to the frame 20 so that the interface 320 can flex andmove when installing the main conductor 800 and the tap conductor 810into the connector 200. In the exemplary embodiment shown in FIG. 13,there are two connecting members 350 used. Each connecting member 350includes a set-screw 352 and an elastomeric bushing 354 positioned onthe set screw 352. The free end of the set screw 352 is passed throughone of the openings 304, seen in FIG. 11, in the rear wall 286 of theframe 280, seen in FIG. 12, into engagement with an aperture 326 in theinterface 320 to mate the interface 320 to the frame 280.

As shown in FIGS. 14-16, in this configuration, the set screws 352 canbe tightened and the bushings 354 allow the interface 320 to flex andmove axially relative to the frame 280 when installing the mainconductor 800 and the tap conductor 810 into the connector 200. Morespecifically, the bushing 354 provides a snap operation when installinga main conductor 800 into the connector 200. The main conductor 800 isinitially positioned in close proximity to the lead-in 283 of the frame280 and the lead-in 322 of the interface 320, seen in FIG. 14, using forexample an extendable reach tool (not shown). The main conductor 800 isthen guided toward the conductor contact wall 282 by the lead-in 283 ofthe frame 280 and the lead-in 322 of the interface 320 where the forceapplied by the main conductor 800 causes the interface lead-in 322 toradially flex toward the wedge body 226 compressing a portion of thebushing 354 and extending another portion of the bushing 354, as seen inFIG. 15. When the main conductor passes the lead-ins 283 and 322, theforce compressing the bushing 354 is removed causing the interface 320to snap back to its normal position as seen in FIG. 16 with the mainconductor 800 positioned between the conductor contact wall 282 and theinterface 320.

Referring now to FIGS. 17 and 18, the electrical connector 200 can beinstalled in the following exemplary manner. The connector 200 is firstassembled where the interface 320 is mated to the frame 280 using theconnecting members 350 of FIGS. 12 and 13, and the wedge 222 is attachedto the frame 280 using the fastener 224 of the wedge assembly 220. Thewedge 222 is attached to the frame 280 so that wedge 222 issubstantially withdrawn from a center of the frame 280, as shown in FIG.17. At this point, the interface 320 is in close proximity to the wedgeassembly 220. The connector 200 is then suspended from a main conductor800 by placing the inner surface 282 a of the conductor contact wall 282onto the main conductor 800 as described above with reference to FIGS.14-16. As described, when placing the inner surface 282 a of theconductor contact wall 282 onto the main conductor 800, the interface320 may need to move axially and/or linearly, e.g., flex, relative tothe frame 280 so that the interface 320 is not obstructing the placementof the inner surface 282 a onto the main conductor 800. A tap conductor810 is then passed, e.g., slid, between the contact surface 326, as seenin FIGS. 14-16, in the interface 320 and the contact surface 244 of thewedge body 226. As the tap conductor 810 is passed between the contactsurface 326 in the interface 320 and the contact surface 244 of thewedge body 226, the interface 320 slides within the frame 280 toward theconductor contact wall 282. As noted above, the stop 300 on the frame280, seen in FIG. 11, may be provided to prevent the interface 320 fromrotating as the interface 320 slides within the frame 280 toward theconductor contact wall 282. With the conductors 800 and 810 positionedwithin the connector 200, the fastener 224 is rotated, e.g., tightened,so that wedge 222 moves toward and into the interior of the frame 280causing the contact surface 244 of the wedge body 226 to engage thebottom surface of the tap conductor 810. As the wedge 222 is furthermoved into the interior of the frame 280, the wedge body 226 pushes thetap conductor 810 into engagement with the contact surface 326 of theinterface 320. Continued movement of the wedge 222 into the interior ofthe frame 280 causes the interface 320 to move upwardly causing thecontact surface 324 of the interface 320 into contact with the mainconductor 800. Continued tightening of the fastener 224 forces the mainconductor 800 against the inner surface 282 a of the conductor contactwall 282 of the frame 280. The fastener 224 is tightened until a stable,electrically conductive path is established between the main conductor800 and the tap conductor 810. In embodiments where the fastener 224 isa shear fastener, the cap nut 58 shears off when sufficient force hasbeen applied by the wedge 222 against the tap conductor 810, theinterface 320, the main conductor 800 and frame 280, as described above.While the above installation embodiment describes the connector 200being suspended from the main conductor 800 first and then the tapconductor 810 being installed, the present disclosure also contemplatesthe tap conductor 810 being installed first and the suspending theconnector 200 and the tap conductor 810 from the main conductor 800.

Referring now to FIGS. 19-43, another exemplary embodiment of aconnector according to the present disclosure is shown and used toelectrically and mechanically connect a main conductor 800 to a tapconductor 810. The connector 400 includes a wedge assembly 420, a frame480, an interface 520 and one or more connecting members 550. The wedgeassembly 420 is operatively coupled to or interconnected with the frame480 so that the wedge assembly 420 can slide or glide along the frame480 to wedge or secure a main conductor 800 to a tap conductor 810 sothat the main conductor 800 and tap conductor 810 are electrically andmechanically connected, as will be described below. The wedge assembly420, frame 480 and interface 520 are made of an electrically conductivematerial that has sufficient rigidity to withstand the forces applied bythe wedge assembly 420 against the frame 480 when mechanicallyconnecting the main conductor 800 to a tap conductor 810. Non-limitingexamples of such electrically conductive and rigid materials includealuminum, aluminum alloys, stainless steel, galvanized steel, copper andcopper/brass alloys. The one or more connecting members 550 may also bemade of an electrically conductive material or a non-conductivematerial. Non-limiting examples of such electrically conductivematerials include the aluminum, aluminum alloys, stainless steel,galvanized steel, copper and copper/brass alloys described above.Non-limiting examples of such non-conductive materials include plasticmaterials and elastomeric materials. For example, the one or moreconnecting members 550 may be made of Ethylene Propylene Diene Monomer(EPDM), Thermoplastic Elastomer (Rubber TPE) or Silicone.

Referring to FIGS. 19-21, 31 and 32, in the exemplary embodiment shown,the wedge assembly 420 includes a wedge 422 and a fastener 424. Thewedge 422 includes a body 426 and a fastener holder 428. The body 426has a front wall 430, a rear wall 432, a top wall 434, a bottom wall 436and side walls 438 and 440. The wedge body 426 is shaped to fit withinthe frame 480. At least a portion of the top wall 434 includes a contactsurface 444, and at least a portion 436 a of the bottom wall 436 is flatand a portion 436 b of the bottom wall 436 extends from the flat portion436 a forming a rail. In the embodiment shown, the bottom wall 436includes two flat portions 436 a provided to glide along the uppersurfaces 484 a and 484 b of the frame 480, and the rail portion 436 b ofthe bottom wall 436 is received within a channel 494 of the frame 480,seen in FIG. 23. The contact surface 444 may be an arcuate surface inthe form of an elongated recess or groove as shown. The contact surface444 is preferably configured to contact a tap conductor 810 positionedin the frame 480. The fastener holder 428 extends from the body 426 andincludes an aperture 446 configured and dimensioned to receive thefastener 424 such that the fastener 424 can rotate relative to theaperture 446. Preferably, the fastener holder 428 is positioned at or inproximity to the rear wall 432 of the body 426 and extends away from theside wall 440 so that the aperture 446 of the fastener holder 428 isaligned with a bore 498, seen in FIG. 19, in the frame 480 when thewedge assembly 420 is coupled to the frame 480. However, the presentdisclosure contemplates that the fastener holder 428 can be positionedat any location on the body 426 so long as the aperture 446 of thefastener holder 428 aligns with the bore 498 in the frame 480, seen inFIG. 24, when the wedge assembly 420 is coupled to the frame 480.

Continuing to refer to FIGS. 19 and 20, the fastener 424 may be anyfastener suitable to releasably secure the wedge assembly 420 to theframe 480 as described herein. In the exemplary embodiment shown, thefastener 424 is the same as the fastener 24 described above such thatlike numerals will be used. Generally, the fastener 424 is an elongatedbolt having a head portion 50 followed by a threaded portion 52. Thehead portion 50 may be, for example, a breakaway head configurationwhere a portion of the head shears or breaks-away from the head portion50. In other embodiments, the head portion 50 may be a conventionalhexagonal bolt head configuration. The head portion 50 shown is abreakaway head configuration described above. A more detaileddescription of a shear type head portion is described in commonly ownedU.S. Pat. No. 10,465,732 which is incorporated herein in its entirety byreference.

Referring to FIGS. 20-23, an exemplary embodiment of the fastener 424attached to the wedge 422 is shown. In the exemplary embodiment shown,the threaded portion 52 of the fastener 424 includes a shoulder 53 thatis configured and dimensioned to fit within the aperture 446 of thefastener holder 428 of the wedge 422 and threading 55. Preferably, theshoulder 53 has a smooth outer surface so that when the shoulder 53 iswithin the aperture 446, the shoulder 53 can freely rotate relative tothe fastener holder 428, which permits the fastener 424 to freelyrotate. Between the shoulder 53 and the threading 55 is a retaininggroove 57 that receives the retaining ring 448 used to at leastpartially attach the fastener 424 to the wedge 422 of the wedge assembly420. The threading 55 on the outer surface of the threaded portion 52 ofthe fastener 424 is complementary to the threading 499 of the threadedbore 498 in the mounting member 496 of the frame 480, which acts as anut. The threading 55 of the threaded portion 52 may be single-leadthreading or multi-lead threading, e.g., double-lead, triple-lead orquadruple-lead threading. In the exemplary embodiment shown in FIGS. 22and 23, the threading 55 is triple-lead threading. With triple-leadthreading there are three independent and continuous helixes “T1”, “T2”and “T3” that have different starting points and that are wrapped aroundthe threaded portion 52 of the fastener 424 forming the threads. It isnoted that the three helixes may also be referred to as ridges and thespacing between the ridges and the pitch of the ridges are typically thesame. Similarly, the corresponding threading in the threaded bore 498also has three independent and continuous helixes “T1”, “T2” and “T3”that have different starting points and form the threaded bore 498. Inthis configuration, each time the threaded portion 52 rotates one turn,i.e., 360°, the fastener 424 advances axially within the threaded bore498 by the width of the number of ridges, here by three ridges. Usingtriple-lead threading permits more rapid movement of the fastener 424and thus the wedge assembly 420 relative to the frame 480 when comparedto single-lead threading. As a result, using triple-lead threadingreduces the installation time to connect the main conductor 800 and thetap conductor 810 to the connector 400. It is noted that the presentdisclosure contemplates that for any embodiment described herein thefastener may have single-lead threading or multi-lead threading, e.g.,double-lead, triple-lead or quadruple-lead threading.

Referring now to FIGS. 19 and 22-24, in the exemplary embodiment shown,the frame 480 is a C-shaped like body or member. The frame 480 has aconductor contact wall 482, a wedge support wall 484, and a rear wall486 between the conductor contact wall 482 and the wedge support wall484. Between the conductor contact wall 482, the wedge support wall 484and the rear wall 486 is a wedge receiving channel 488. The wedgereceiving channel 488 at a first end 490 of the frame 480 has a length“L1” and the wedge receiving channel 488 at a second end 492 of theframe 480 has a length “L2.” In the embodiment shown, the length “L1” isless than the length “L2” such that one or both of the conductor contactwall 482 and the wedge support wall 484 are tapered relative to alongitudinal axis “A” of the frame 480. In the embodiment shown, thewedge support wall 484 is at an angle “α” relative to a longitudinalaxis “A” of the frame 480. The angle “α” may be in the range of about 5degrees to about 25 degrees. In the embodiment shown, the conductorcontact wall 482, the wedge support wall 484, the rear wall 486 and thewedge receiving channel 488 form the C-shaped like body or member. Theframe 480 may also include a stop member 500, seen in FIG. 22, used toprevent longitudinal movement of the interface 520 along axis “A” whenmated with the frame 480. The stop member 500 may also limit andpossibly prevent rotation of the interface 520 when tightening thefastener 424 to secure the main conductor 800 and the tap conductor 810to the frame 480.

The conductor contact wall 482 has an inner surface 482 a, an outersurface 482 b and a lead-in 483. The inner surface 482 a of theconductor contact wall 482 is shaped, e.g., arcuate shaped, to form aconductor groove that is configured and dimensioned to receive or fit atleast partially around a main conductor 800. The lead-in 483 helps toguide the main conductor 800 toward and into the conductor contact wall482. The wedge support wall 484 includes one or more upper surfaces andthe channel 494. In the embodiment shown, the wedge support wall 484includes two upper surfaces 484 a and 484 b. The upper surfaces 484 aand 484 b are configured and dimensioned to interact with the flatportions 436 a of the bottom wall 436 of the wedge body 426 so that thewedge body 426 can glide along the upper surfaces 484 a and 484 b whenthe wedge body 426 moves between the loading position and the clampingposition. It is noted that in the loading position a center of the wedgebody 426 is away from a center of the frame 480 sufficient so that themain conductor 800 and the tap conductor 810 can be installed in theframe 480. In the clamping position a center of the wedge body 426 isclose to a center of the frame 480 sufficient so that the main conductor800 and the tap conductor 810 are electrically and mechanicallyconnected.

In the exemplary embodiment shown, the wedge support wall 484 also hasan inner surface 484 c and an outer surface 484 d, seen in FIG. 24. Theinner surface 484 c of the wedge support wall 484 is shaped, e.g., aU-shape like structure, to form the channel 494 that is configured anddimensioned to receive the fastener 424. The wedge support wall 484 ofthe frame 480 includes a mounting member or tab 496 extending from thewedge support wall 484 and/or the rear wall 486, as shown. The mountingmember 496 is a substantially solid member having an internally threadedbore 498 that passes through the mounting member 496. The threaded bore498 is configured and dimensioned to receive the fastener 424. Themounting member 496 may be positioned at any point along the channel 494of the wedge support wall 484. In the exemplary embodiment shown in FIG.24, the mounting member 496 is positioned in close proximity to thesecond end 492 of the frame 480. The mounting member 496 may beintegrally or monolithically formed into the wedge support wall 484and/or the rear wall 486, or the mounting member 496 may be secured tothe wedge support wall 484 and/or the rear wall 486 using welds,mechanical fasteners or adhesives. The wedge support wall 484 may alsoinclude an eyelet 502 used for connecting an extendable reach tool (notshown) to the connector 400.

The rear wall 486 of the frame 480 is a substantially flat wall havingone or more openings 504, e.g., slots, through which the connectingmember 550 may pass to mate the interface 520 to the frame 480. In theexemplary embodiment of FIG. 22 there are two openings 504. But, asdescribed above, there may be a single opening, or other opening, suchas the T-shaped opening described above. Surrounding each opening 504 inthe rear wall 486 is a recessed portion 506 configured to receive aninterface coupling member 556 of a connecting member 550 to reduce thedistance the connecting member 550 extends from the rear wall 486.

An exemplary embodiment of the interface 520 is shown in FIGS. 19 and23-25. The interface 520 is an elongated body having a predefined length“L3” and a width “W2.” In the exemplary embodiment shown, the interface520 has a length “L3” that is substantially the same as a width “W” ofthe frame 480. In the exemplary embodiment shown, the interface 520 is arectangular body having first and second ends 520 a and 520 b, and firstand second side walls 520 c and 520 d. A lead-in 522 may extend fromeither the first side wall 520 c or the second side wall 520 d. Acontact surface 524 is formed in an upper surface of the interface 520,and a contact surface 526 is formed in a lower surface of the interface520. The contact surface 524 is configured and dimensioned to receive orfit at least partially around a main conductor 800. The contact surface526 is configured and dimensioned to receive or fit at least partiallyaround a tap conductor 810. As shown in FIG. 29, when the wedge assembly420 is coupled to the frame 480 and the interface 520 is positionedbetween a main conductor 800 and a tap conductor 810, the contactsurface 524 contacts a lower surface of the main conductor 800 and thecontact surface 526 contacts an upper surface of the tap conductor 810.It is noted that the main conductor 800 and tap conductor 810, shown inFIG. 29, have substantially the same outer diameter. Accordingly, thecontact surface 524 and 526 formed in the upper and lower surfaces ofthe interface 520 have substantially the same configuration. However, insome instances it may be desirable to connect a tap conductor having asmaller outer diameter to a main conductor having a larger outerdiameter. In such situations, the contact surface 524 would beconfigured to engage the larger outer diameter main conductor 800 andthe contact surface 526 would be configured to engage the smaller outerdiameter tap conductor 810.

Either the first side wall 520 c or the second side wall 520 d of theinterface 520 includes a mounting element 528, e.g., a channel,configured and dimensioned to interact with the connecting members 550.As shown in FIGS. 23-25, the connecting members 550 are provided to beattached to the interface 520 and to mate the interface 520 to the frame480 so that the interface 520 can flex and move when installing the mainconductor 800 and the tap conductor 810 into the connector 400. In theexemplary embodiment shown in FIGS. 23 and 25, there are two connectingmembers 550 used. Each connecting member 550 includes an elastomericbase 552 and an elastomeric leg 554. The base 552 is configured anddimensioned to fit within the recess 506 on the rear wall 486 of theframe 480 and is provided to prevent the connecting member 550 fromfully passing through the opening 504 in the rear wall 486. The base 552also has an arcuate shape as, seen in FIG. 25, such that there is anangle between the leg 554 and the free ends of the base 552. This anglecreates a linear distance from the free end of the base 552 and aportion of the base 552 from which the leg 554 attaches to the base 552.This linear distance determines a stroke length of the spring action ofthe connecting member 550. The leg 554 extends from the base 552 and endwith an interface coupling member 556 that is configured and dimensionedto fit within the mounting element 528, e.g., the channel, of theinterface 520. The leg 554 may be integrally or monolithically formedinto the base 552 or the leg 554 may be secured to the base 552 usingfor example adhesives. The interface coupling member 556 of the leg 554is passed through one of the openings 504 in the rear wall 486 of theframe 480, seen in FIG. 22, into engagement with the channel 528 of theinterface 520, which is acting as the mounting element. In the exemplaryembodiment of FIG. 23, the interface coupling member 556 of the leg 554is slid into engagement with the channel 528 of the interface 520. Inother exemplary embodiments, the interface coupling member 556 of theleg 554 can be snapped into engagement with the channel 528 of theinterface 520.

As shown in FIGS. 26-28, in this configuration, the interface couplingmember 556 and leg 554 allow the interface 520 to flex and move axiallyrelative to the frame 480 when installing the main conductor 800 and thetap conductor 810 into the connector 400. In addition, as noted abovethe leg 554 is made of an elastomeric material that allows the leg 554and thus the interface 520 to further flex and move axially relative tothe frame 480. More specifically, the leg 554 and interface couplingmember 556 provide a snap operation when installing a main conductor 800into the connector 400. The main conductor 800 is initially positionedin close proximity to the lead-in 483 of the frame 480 and the lead-in522 of the interface 520, seen in FIG. 26, using for example anextendable reach tool (not shown). The main conductor 800 is then guidedtoward the conductor contact wall 482 by the lead-in 483 of the frame480 and the lead-in 522 of the interface 520 where the force applied bythe main conductor 800 causes the interface lead-in 522 to radially flextoward the wedge assembly 420 extending the leg 554 of the connectingmembers 550, as seen in FIG. 27. When the main conductor passes thelead-ins 483 and 522, the force extending the leg 554 is removed causingthe interface 520 to return back to its normal position, as seen in FIG.28.

Referring now to FIGS. 29 and 30, the electrical connector 400 can beinstalled in the following exemplary manner. The connector 400 is firstassembled where the interface 520 is mated to the frame 480 using theconnecting members 550 of FIGS. 24 and 25, and the wedge 422 is attachedto the frame 480 using the fastener 424 of the wedge assembly 420. Thewedge 422 is attached to the frame 480 so that wedge 422 issubstantially withdrawn from a center of the frame 480, as shown in FIG.29. At this point, the interface 520 is in close proximity to the wedgeassembly 420. The connector 400 is then suspended from a main conductor800 by placing the inner surface 482 a of the conductor contact wall 482onto the main conductor 800 as described above with reference to FIGS.26-28. As described, when placing the inner surface 482 a of theconductor contact wall 482 onto the main conductor 800, the interface520 may need to move axially and/or linearly, e.g., flex, relative tothe frame 480 so that the interface 520 is not obstructing the placementof the inner surface 482 a onto the main conductor 800. A tap conductor810 is then passed, e.g., slid, between the contact surface 526 in theinterface 520 and the contact surface 444 of the wedge body 426. As thetap conductor 810 is passed between the contact surface 526 in theinterface 520 and the contact surface 444 of the wedge body 426, theinterface 520 slides within the frame 480 toward the conductor contactwall 482. As noted above, the stop 500 on the frame 480, seen in FIG.22, may be provided to prevent the interface 520 from rotating as theinterface 520 slides within the frame 480 toward the conductor contactwall 482. With the conductors 800 and 810 positioned within theconnector 400, the fastener 424 is rotated, e.g., tightened, so thatwedge 422 moves toward and into the interior of the frame 480 causingthe contact surface 444 of the wedge body 426 to engage the bottomsurface of the tap conductor 810. As the wedge 422 is further moved intothe interior of the frame 480, the wedge body 426 pushes the tapconductor 810 into engagement with the contact surface 526 of theinterface 520. Continued movement of the wedge 422 into the interior ofthe frame 480 causes the interface 520 to move upwardly causing thecontact surface 524 of the interface 520 into contact with the mainconductor 800. Continued tightening of the fastener 424 forces the mainconductor 800 against the inner surface 482 a of the conductor contactwall 482 of the frame 480. The fastener 424 is tightened until a stable,electrically conductive path is established between the main conductor800 and the tap conductor 810. In embodiments where the fastener 424 isa shear fastener, the cap nut 58 shears off when sufficient force hasbeen applied by the wedge 422 against the tap conductor 810, theinterface 520, the main conductor 800 and frame 480, as described above.While the above installation embodiment describes the connector 400being suspended from the main conductor 800 first and then the tapconductor 810 being installed, the present disclosure also contemplatesthe tap conductor 810 being installed first and then suspending theconnector 400 and the tap conductor 810 from the main conductor 800.

Referring now to FIGS. 31-41, another exemplary embodiment of aconnector according to the present disclosure is shown and used toelectrically and mechanically connect a main conductor 800 to a tapconductor 810. The connector 600 includes a wedge assembly 620, a frame680, an interface 720 and one or more connecting members 750. The wedgeassembly 620 is operatively coupled to or interconnected with a frame680 so that the wedge assembly 620 can slide or glide along the frame680 to wedge or secure the main conductor 800 to the tap conductor 810so that the main conductor 800 and tap conductor 810 are electricallyand mechanically connected, as will be described below. The wedgeassembly 620, frame 680 and interface 720 are made of an electricallyconductive material that has sufficient rigidity to withstand the forcesapplied by the wedge assembly 620 against the frame 680 whenmechanically connecting the main conductor 800 to the tap conductor 810.Non-limiting examples of such electrically conductive and rigidmaterials include aluminum, aluminum alloys, stainless steel, galvanizedsteel, copper and copper/brass alloys. The one or more connectingmembers 750 may also be made of an electrically conductive material or anon-conductive material. Non-limiting examples of such electricallyconductive materials include aluminum, aluminum alloys, stainless steel,galvanized steel, copper and copper/brass alloys described above.Non-limiting examples of such non-conductive materials include plasticmaterials and elastomeric materials. For example, the one or moreconnecting members 750 may be made of Ethylene Propylene Diene Monomer(EPDM), Thermoplastic Elastomer (Rubber TPE) or Silicone.

Referring to FIGS. 31 and 32, in the exemplary embodiment shown, thewedge assembly 620 includes a wedge 622 and a fastener 624. The wedge622 includes a body 626, a fastener holder 628 and a fastener guide 630.The body 626 has a front wall 632, a rear wall 634, a top wall 636, abottom wall 638 and side walls 640 and 642. The wedge body 626 is shapedto fit within the frame 680. At least a portion of the top wall 636includes a contact surface 644 that may be an arcuate surface in theform of an elongated recess or groove as shown. The contact surface 644is preferably configured to contact a tap conductor 810 positioned inthe frame 680. The bottom wall 638 is substantially flat, and includesthe fastener guide 630 extending therefrom. The fastener guide 630 isconfigured to be received within a channel 694, seen in FIG. 34, of theframe 680. In this exemplary embodiment, the fastener guide 630 includesa rail 646 having an aperture 648 therethrough in which a distal end ofthe fastener 424 rests. The fastener holder 628 extends from the body626 and includes an aperture 650 configured and dimensioned to receivethe fastener 624 such that the fastener 624 can rotate relative to theaperture 650. In this exemplary embodiment, the fastener holder 628 ispositioned at or in proximity to the rear wall 634 of the body 626 andextends away from the bottom wall 638 so that the aperture 650 of thefastener holder 628 is aligned with an aperture 698 in the frame 680,seen in FIG. 34, and with the aperture 648 in the rail 646 when thewedge assembly 620 is coupled to the frame 680. However, the presentdisclosure contemplates that the fastener holder 628 can be positionedat any location on the body 626 so long as the aperture 650 of thefastener holder 628 aligns with the aperture 698 in the frame 680 andwith the aperture 648 in the rail 646 when the wedge assembly 620 iscoupled to the frame 680.

Continuing to refer to FIGS. 31 and 32, the fastener 624 may be anyfastener suitable to releasably secure the wedge assembly 620 to theframe 680 as described herein. In the exemplary embodiment shown, thefastener 624 is the same as the fastener 24 described above such thatlike numerals will be used. Generally, the fastener 624 is an elongatedbolt having a head portion 50 followed by a threaded portion 52. Thehead portion 50 may be, for example, a breakaway head configurationwhere a portion of the head shears or breaks-away from the head portion50. In other embodiments, the head portion 50 may be a conventionalhexagonal bolt head configuration. The head portion 50 shown is abreakaway head configuration described above. A more detaileddescription of a shear type head portion is described in commonly ownedU.S. Pat. No. 10,465,732 which is incorporated herein in its entirety byreference. The fastener 624 is attached to the wedge 622 using aretaining ring 645.

Referring now to FIGS. 31 and 33-35, in the exemplary embodiment shown,the frame 680 is a C-shaped like body or member. The frame 680 has aconductor contact wall 682, a wedge support wall 684, and a rear wall686 between the conductor contact wall 682 and the wedge support wall684. Between the conductor contact wall 682, the wedge support wall 684and the rear wall 686 is a wedge receiving channel 688. The wedgereceiving channel 688 at a first end 690 of the frame 680 has a length“L1” and the wedge receiving channel 688 at a second end 692 of theframe 680 has a length “L2.” In the embodiment shown, the length “L1” isless than the length “L2” such that one or both of the conductor contactwall 682 and the wedge support wall 684 are tapered relative to alongitudinal axis “A” of the frame 680. In the embodiment shown, thewedge support wall 684 is at an angle “α” relative to a longitudinalaxis “A” of the frame 680. The angle “α” may be in the range of about 5degrees to about 25 degrees. In the embodiment shown, the conductorcontact wall 682, the wedge support wall 684, the rear wall 686 and thewedge receiving channel 688 form the C-shaped like body or member. Theframe 680 may also include a stop member 700, seen in FIG. 33, used toprevent longitudinal movement of the interface 720 along axis “A” whenmated with the frame 680. The stop member 700 may also limit andpossibly prevent rotation of the interface 720 when tightening thefastener 624 to secure the main conductor 800 and the tap conductor 810to the frame 680.

Continuing to refer to FIGS. 31 and 33-35, the conductor contact wall682 has an inner surface 682 a, an outer surface 682 b and a lead-in683. The inner surface 682 a of the conductor contact wall 682 isshaped, e.g., arcuate shaped, to form a conductor groove that isconfigured and dimensioned to receive or fit at least partially around amain conductor 800. The lead-in 683 helps to guide the main conductor800 toward and into the conductor contact wall 682. The wedge supportwall 684 includes one or more upper surfaces and the channel 694. In theembodiment shown, the wedge support wall 684 includes two upper surfaces684 a and 684 b. The upper surfaces 684 a and 684 b are configured anddimensioned to interact with the flat bottom wall 638, seen in FIG. 32,of the wedge body 626 so that the wedge body 626 can glide along theupper surfaces 684 a and 684 b when the wedge body 626 moves between theloading position and the clamping position. It is noted that in theloading position a center of the wedge body 626 is away from a center ofthe frame 680 sufficient so that the main conductor 800 and the tapconductor 810 can be installed in the frame 680. In the clampingposition a center of the wedge body 626 is close to a center of theframe 680 sufficient so that the main conductor 800 and the tapconductor 810 are electrically and mechanically connected.

In the exemplary embodiment shown, the wedge support wall 684 alsoincludes an inner surface 684 c and an outer surface 684 d. The innersurface 684 c of the wedge support wall 684 is shaped, e.g., a U-shapelike structure, to form the channel 694, seen in FIG. 34, that isconfigured and dimensioned to receive the fastener 624 and the rail 646,seen in FIG. 32, extending from the wedge body 626, such that thechannel 694 acts as a track. The wedge support wall 684 of the frame 680includes a mounting member or tab 696 extending from the wedge supportwall 484 and/or the rear wall 486 into the channel 694, as shown. Themounting member 696 is a substantially solid member having an internallythreaded bore 698 that passes through the mounting member 696. Thethreaded bore 698 is configured and dimensioned to receive the fastener624. The mounting member 696 may be positioned at any point along thechannel 694 of the wedge support wall 684. In the exemplary embodimentshown in FIGS. 31 and 35, the mounting member 696 is positioned in closeproximity to the second end 692 of the frame 680. The mounting member696 may be integrally or monolithically formed into the wedge supportwall 684 and/or the rear wall 686, or the mounting member 696 may besecured to the wedge support wall 684 and/or the rear wall 686 usingwelds, mechanical fasteners or adhesives. The wedge support wall 684 mayalso include an eyelet 702 used for connecting an extendable reach tool(not shown) to the connector 600.

Referring to FIGS. 31 and 34, the rear wall 686 of the frame 680 is asubstantially flat wall having one or more openings 704, e.g., slots,through which the connecting member 750 may pass to mate the conductorinterface 720 to the frame 680. In the exemplary embodiment of FIG. 34there is a single opening 704. But, as described above, there may bemultiple openings, or other opening, such as the T-shaped openingdescribed above.

An exemplary embodiment of the conductor interface 720 is shown in FIGS.34 and 36. The interface 720 is an elongated body having a predefinedlength “L3” and a width “W2.” In the exemplary embodiment shown, theinterface 720 has a length “L3” that is substantially the same as awidth “W” seen in FIG. 33, of the frame 680. In the exemplary embodimentshown, the interface 720 is a rectangular body having first and secondends 720 a and 720 b, and first and second side walls 720 c and 720 d. Afirst or upper lead-in 722 may extend from either the first side wall720 c or the second side wall 720 d, and a second or lower lead-in 724may extend from either the first side wall 720 c or the second side wall720 d. The upper lead-in 722 is provided to guide the main conductor 800toward the conductor contact wall 682, and the lower lead-in 724 isprovided to guide the tap conductor 810 toward the contact surface 644of the wedge 622. A contact surface 726 is formed in an upper surface ofthe interface 720, and a contact surface 728 is formed in a lowersurface of the interface 720. The contact surface 726 is configured anddimensioned to receive or fit at least partially around the mainconductor 800. The contact surface 728 is configured and dimensioned toreceive or fit at least partially around the tap conductor 810. As shownin FIGS. 40 and 41, when the wedge assembly 620 is coupled to the frame680 and the interface 720 is positioned between the main conductor 800and the tap conductor 810, the contact surface 726 contacts a lowersurface of the main conductor 800 and the contact surface 728 contactsan upper surface of the tap conductor 810. It is noted that the mainconductor 800 and tap conductor 810, shown in FIGS. 40 and 41, havesubstantially the same outer diameter. Accordingly, the contact surfaces726 and 728 formed in the upper and lower surfaces of the interface 720have substantially the same configuration. However, in some instances itmay be desirable to connect a tap conductor having a smaller outerdiameter to a main conductor having a larger outer diameter. In suchsituations, the contact surface 726 would be configured to engage thelarger outer diameter main conductor 800 and the contact surface 728would be configured to engage the smaller outer diameter tap conductor810.

Either the first side wall 720 c or the second side wall 720 d of theinterface 720 includes a mounting element 730, e.g., a channel,configured and dimensioned to interact with or couple to the connectingmember 750. As shown in FIGS. 34 and 36, the connecting member 750 isprovided to be attached to the interface 720 and to mate the interface720 to the frame 680 so that the interface 720 can flex and move wheninstalling the main conductor 800 and the tap conductor 810 into theconnector 600. In the exemplary embodiment shown in FIGS. 33 and 35,there is a single connecting member 750 used. The connecting member 750includes an elastomeric base 752 and an elastomeric leg 754. The base752 is configured and dimensioned to fit within the recess 704 on therear wall 686, seen in FIG. 33, of the frame 680 and is provided toprevent the connecting member 750 from fully passing through the opening704 in the rear wall 686. In the embodiment shown, the base 752 has anarcuate shape, seen in FIG. 36, such that there is an angle between theleg 754 and the free ends of the base 752. This angle creates a lineardistance from the free end of the base 752 and a portion of the base 752from which the leg 754 attaches to the base 752. This linear distancedetermines a stroke length of the spring action of the connecting member750. The leg 754 extends from the base 752 and ends with an interfacecoupling member 756 that is configured and dimensioned to fit within themounting element 730, e.g., the channel, of the interface 720. The leg754 may be integrally or monolithically formed into the base 752 or theleg 754 may be secured to the base using for example adhesives. Theinterface coupling member 756 of the leg 754 is passed through one ofthe openings 704 in the rear wall 686 of the frame 680, seen in FIG. 34,into engagement with the channel 730 of the interface 720, which isacting as the mounting element. In the exemplary embodiment of FIG. 36,the interface coupling member 756 of the leg 754 can be slid intoengagement with the channel 730 of the interface 720. In anotherexemplary embodiment, the interface coupling member 756 of the leg 754can be snapped into engagement with the channel 730 of the interface720.

As shown in FIGS. 37-39, in this configuration, the interface couplingmember 756 and leg 754 allow the interface 720 to flex and move axiallyrelative to the frame 680 when installing the main conductor 800 and thetap conductor 810 into the connector 600. In addition, as noted abovethe leg 754 is made of an elastomeric material that allows the leg 754and thus the interface 720 to further flex and move axially relative tothe frame 680. More specifically, the leg 754 and interface couplingmember 756 provide a snap operation when installing a main conductor 800into the connector 600. The main conductor 800 is initially positionedin close proximity to the lead-in 683 of the frame 680 and the lead-in722 of the interface 720, seen in FIG. 37, using for example anextendable reach tool (not shown). The main conductor 800 is then guidedtoward the conductor contact wall 682 by the lead-in 683 of the frame680 and the lead-in 722 of the interface 720 where the force applied bythe main conductor 800 causes the interface lead-in 722 to radially flextoward the wedge assembly 620 extending the leg 654 of the connectingmember 750, as seen in FIG. 38. When the main conductor passes thelead-ins 683 and 722, the force extending the leg 754 is removed causingthe interface 720 to return (e.g., snap back) back to its normalposition, as seen in FIG. 39.

Referring now to FIGS. 40 and 41, the electrical connector 600 can beinstalled in the following exemplary manner. The connector 600 is firstassembled where the interface 720 is mated to the frame 680 using theconnecting members 750 of FIGS. 35 and 36, and the wedge 622 is attachedto the frame 680 using the fastener 624 of the wedge assembly 620. Thewedge 622 is attached to the frame 680 so that wedge 622 issubstantially withdrawn from a center of the frame 680, as shown in FIG.40. At this point, the interface 720 is in close proximity to the wedgeassembly 620. The connector 600 is then suspended from a main conductor800 by placing the inner surface 682 a of the conductor contact wall 682onto the main conductor 800 as described above with reference to FIGS.37-39. As described, when placing the inner surface 682 a of theconductor contact wall 682 onto the main conductor 800, the interface720 may need to move axially and/or linearly, e.g., flex, relative tothe frame 680 so that the interface 720 is not obstructing the placementof the inner surface 682 a onto the main conductor 800. A tap conductor810 is then passed, e.g., slid, between the contact surface 728 in theinterface 720 and the contact surface 644 of the wedge body 626. As thetap conductor 810 is passed between the contact surface 728 in theinterface 720 and the contact surface 644 of the wedge body 626, theinterface 720 slides within the frame 680 toward the conductor contactwall 682. As noted above, the stop 700 on the frame 680, seen in FIG.33, may be provided to prevent the interface 720 from rotating as theinterface 720 slides within the frame 680 toward the conductor contactwall 682. With the conductors 800 and 810 positioned within theconnector 600, the fastener 624 is rotated, e.g., tightened, so thatwedge 622 moves toward and into the interior of the frame 680 causingthe contact surface 644 of the wedge body 626 to engage the bottomsurface of the tap conductor 810. As the wedge 622 is further moved intothe interior of the frame 680, the wedge body 626 pushes the tapconductor 810 into engagement with the contact surface 728 of theinterface 720. Continued movement of the wedge 622 into the interior ofthe frame 680 causes the interface 720 to move upwardly causing thecontact surface 726 of the interface 720 into contact with the mainconductor 800. Continued tightening of the fastener 624 forces the mainconductor 800 against the inner surface 682 a of the conductor contactwall 682 of the frame 680. The fastener 624 is tightened until a stable,electrically conductive path is established between the main conductor800 and the tap conductor 810. In embodiments where the fastener 624 isa shear fastener, the cap nut 58 shears off when sufficient force hasbeen applied by the wedge 622 against the tap conductor 810, theinterface 720, the main conductor 800 and frame 680, as described above.While the above installation embodiment describes the connector 600being suspended from the main conductor 800 first and then the tapconductor 810 being installed, the present disclosure also contemplatesthe tap conductor 810 being installed first and the suspending theconnector 600 and the tap conductor 810 from the main conductor 800.

Referring now to FIGS. 42-47, another exemplary embodiment of aconnector according to the present disclosure is shown and used toelectrically and mechanically connect a main conductor 800 to a tapconductor 810. The connector 900 is substantially similar to theconnector 600 described above with reference to FIGS. 31-41 such thatlike numerals are used for like components. In this exemplaryembodiments, the connector 900 includes the wedge assembly 620, theframe 680, the interface 720 and one or more connecting members 750. Thewedge assembly 620 is substantially similar to the wedge assembly 620described above and a detailed description thereof is not repeated.However, in this exemplary embodiment, the fastener guide 630 ispositioned in close proximity to the front wall 632 of the wedge body626, as seen in FIG. 44. The fastener 624 is an elongated bolt having ahead portion 50 followed by a threaded portion 52 followed by anunthreaded portion 51. For ease of description, the head portion 50 andthreaded portion 52 are described above and a detailed descriptionthereof is not repeated. In this exemplary embodiment, the unthreadedportion 51 is elongated sufficient to permit a rapid advance of thewedge 622 of the wedge assembly 620 toward the center of the body 680,as shown in FIGS. 45-47, allowing the connector 900 to accommodatelarger size and smaller size conductors 800 and/or 810 withoutincreasing the time to install such conductors. In addition, theelongated unthreaded portion 51 of the fastener 624 permits the wedge622 to be withdrawn further out of the frame 680 creating a wider gapbetween the top wall 636 of the wedge body 626 and the interface 720 anda wider gap between the top wall 636 of the wedge body 626 and edge 682c of the conductor contact wall 682 than would exist if the threadedportion 52 of the fastener 624 were threaded into the threaded bore 698in the mounting member 696. For example, in FIG. 45, the gap “G1”between the top wall 636 of the wedge body 626 and the interface 720would be at a minimum in the range that permits unobstructed insertionof the main conductor 800 and the tap conductor 810 into the connector900. And the gap “G1′ ” between the top wall 636 of the wedge body 626and edge 682 c of the conductor contact wall 682 would be at a minimumin the range that permits unobstructed insertion of the main conductor800 and the tap conductor 810 into the connector 900. In FIG. 46, thewedge 622 is withdrawn out of the frame 680 creating a gap “G2” betweenthe top wall 636 of the wedge body 626 and the interface 720 that islarger than the gap G1 and creating a gap “G2′ ” between the top wall636 of the wedge body 626 and the edge 682 c of the conductor contactwall 682 that is larger than the gap “G1′”. And, in FIG. 47, the wedge622 is withdrawn further out of the frame 680 creating a gap “G3”between the top wall 636 of the wedge body 626 and the interface 720 isat a maximum, which is larger than the gaps G1 and G2, and in a rangethat permits unobstructed insertion of a larger main conductor 900 and alarger tap conductor 810 into the connector 800. And, creating a gap“G3′ ” between the top wall 636 of the wedge body 626 and the edge 682 cof the conductor contact wall 682 that is at a maximum, which is largerthan the gaps G1′ and G2′, and in a range that permits unobstructedinsertion of a larger main conductor 800 and a larger tap conductor 810into the connector 900.

In the exemplary embodiment of FIGS. 42-47, the frame 680 may alsoinclude a second stop member 701, seen in FIG. 43, that can preventlongitudinal movement of the interface 720 along axis “A” of the frame680 when the interface 720 is mated with the frame 680. The second stopmember 701 may also limit and possibly prevent rotation of the interface720 when tightening the fastener 624 to secure the main conductor 800and the tap conductor 810 to the frame 680.

Referring now to FIGS. 48-53, another exemplary embodiment of aconnector according to the present disclosure is shown and used toelectrically and mechanically connect a main conductor 800 to a tapconductor 810. The connector 950 is substantially similar to theconnector 600 described above with reference to FIGS. 31-41, and theconnector 900 described above with reference to FIGS. 42-47, such thatlike numerals are used for like components. In this exemplaryembodiments, the connector 950 includes a wedge assembly 960, a frame970, an interface 720 and one or more connecting members 750. The wedgeassembly 960 is substantially similar to the wedge assembly 620described above such that like reference numerals are used and adetailed description of the similar features are not repeated. The frame970 is substantially similar to the frame 680 described above such thatlike reference numerals are used and a detailed description of thesimilar features are not repeated.

In this exemplary embodiment, the frame 970 is a C-shaped like body ormember. The frame 970 has a conductor contact wall 682, a wedge supportwall 684, and a rear wall 686 between the conductor contact wall 682 andthe wedge support wall 684. Between the conductor contact wall 682, thewedge support wall 684 and the rear wall 686 is a wedge receivingchannel 688. The wedge receiving channel 688 at a first end 690 of therear wall 686 has a length “L1” and the wedge receiving channel 688 at asecond end 692 of the rear wall 686 has a length “L2” similar to thatseen in FIG. 33. In the embodiment shown, the length “L1” is less thanthe length “L2” such that one or both of the conductor contact wall 682and the wedge support wall 684 are tapered relative to a longitudinalaxis “A” of the frame 970. In the embodiment shown, the wedge supportwall 684 is at an angle “α” relative to a longitudinal axis “A” of theframe 970. The angle “α”, similar to the angle seen in FIG. 33, may bein the range of about 5 degrees to about 25 degrees. In the embodimentshown, the conductor contact wall 682, the wedge support wall 684, therear wall 686 and the wedge receiving channel 688 form the C-shaped likebody or member.

Continuing to refer to FIGS. 48-53, the first end 690 of the rear wall686 has an ear 972 extending therefrom so that the ear 972 is in thesame plane as the rear wall 686. Similarly, the second end 692 of therear wall 686 has an ear 974 extending therefrom so that the ear 974 isin the same plane as the rear wall 686. The ears 972 and 974 extend thewidth of the rear wall 686 of the frame 970, as shown in FIG. 50. It isnoted that by extending the width of the rear wall 686, the length “L3”of the conductor interface 720 would be increased so that the connectingmembers 750 can couple the conductor interface 720 to the frame 970.

The ear 972 is a substantially flat wall that is integrally ormonolithically formed into the rear wall 686 or is secured to the rearwall using, for example, welds, adhesives or fasteners. The ear 972 hasone or more openings 976, e.g., slots, through which the connectingmember 750 may pass to mate the conductor interface 720 to the frame 970as described hereinabove. In the exemplary embodiment of FIG. 50 thereis a single opening 976. But, as described above, there may be multipleopenings, or other opening, such as the T-shaped opening describedabove. The ear 972 may also include a stop member 980, seen in FIG. 50,used to prevent longitudinal movement of the interface 720 along axis“A” when mated with the frame 970. The stop member 980 may also limitand possibly prevent rotation of the interface 720 when tightening thefastener 624 to secure the main conductor 800 and the tap conductor 810to the frame 970.

Continuing to refer to FIG. 50, the ear 974 is a substantially flat wallthat is integrally or monolithically formed into the rear wall 686 or issecured to the rear wall using, for example, welds, adhesives orfasteners. The ear 974 has one or more openings 978, e.g., slots,through which the connecting member 750 may pass to mate the conductorinterface 720 to the frame 970 as described hereinabove. In theexemplary embodiment of FIG. 50 there is a single opening 978. But, asdescribed above, there may be multiple openings, or other opening, suchas the T-shaped opening described above. The ear 974 may include a stopmember 982 used to prevent longitudinal movement of the interface 720along axis “A” when mated with the frame 970. The stop member 982 mayalso limit and possibly prevent rotation of the interface 720 whentightening the fastener 624 to secure the main conductor 800 and the tapconductor 810 to the frame 970.

Referring now to FIGS. 52 and 53, the electrical connector 950 can beinstalled in the following exemplary manner. The connector 950 is firstassembled where the interface 720 is mated to the frame 970 using theconnecting members 750 of FIG. 49, and the wedge 622 is attached to theframe 970 using the fastener 624 of the wedge assembly 620. The wedge622 is attached to the frame 970 so that wedge 622 is withdrawn from acenter of the frame 970 sufficient to permit the conductors 800 and 810to be installed on the connector 950, as described herein. At thispoint, the interface 720 is in close proximity to the wedge assembly620. The connector 950 is then suspended from a main conductor 800 byplacing the inner surface 682 a of the conductor contact wall 682 ontothe main conductor 800, as described above with reference to, forexample, FIGS. 37-39. As described, when placing the inner surface 682 aof the conductor contact wall 682 onto the main conductor 800, theinterface 720 may need to move axially and/or linearly, e.g., flex,relative to the frame 970 so that the interface 720 is not obstructingthe placement of the inner surface 682 a onto the main conductor 800. Atap conductor 810 is then passed, e.g., slid, between the contactsurface 728 of the interface 720 and the contact surface 644 of thewedge body 626. As the tap conductor 810 is passed between the contactsurface 728 in the interface 720 and the contact surface 644 of thewedge body 626, the interface 720 slides within the frame 970 toward theconductor contact wall 682. As noted above, the stops 972 and 974 on theframe ears 972 and 974 of the frame 970, seen in FIG. 50, may beprovided to prevent the interface 720 from moving linearly and rotatingas the interface 720 slides relative to the frame 970 toward theconductor contact wall 682. With the conductors 800 and 810 positionedwithin the connector 950, the fastener 624 is rotated, e.g., tightened,so that wedge 622 moves toward and into the interior of the frame 970causing the contact surface 644 of the wedge body 626 to engage thebottom surface of the tap conductor 810. As the wedge 622 is furthermoved into the interior of the frame 970, the wedge body 626 pushes thetap conductor 810 into engagement with the contact surface 728 of theinterface 720. Continued movement of the wedge 622 into the interior ofthe frame 970 causes the interface 720 to move upwardly causing thecontact surface 726 of the interface 720 into contact with the mainconductor 800. Continued tightening of the fastener 624 forces the mainconductor 800 against the inner surface 682 a of the conductor contactwall 682 of the frame 970. The fastener 624 is tightened until a stable,electrically conductive path is established between the main conductor800 and the tap conductor 810. In embodiments where the fastener 624 isa shear fastener, the cap nut 58 shears off when sufficient force hasbeen applied by the wedge 622 against the tap conductor 810, theinterface 720, the main conductor 800 and frame 970, as described above.While the above installation embodiment describes the connector 950being suspended from the main conductor 800 first and then the tapconductor 810 being installed, the present disclosure also contemplatesthe tap conductor 810 being installed first and the suspending theconnector 970 and the tap conductor 810 from the main conductor 800.

While illustrative embodiments of the present disclosure have beendescribed and illustrated above, it should be understood that these areexemplary of the disclosure and are not to be considered as limiting.Additions, deletions, substitutions, and other modifications can be madewithout departing from the spirit or scope of the present disclosure.Accordingly, the present disclosure is not to be considered as limitedby the foregoing description.

What is claimed is:
 1. A wedge type electrical power connector assemblycomprising: a frame having conductor contact wall, a wedge support wall,a rear wall and a mounting member, the rear wall being between theconductor contact wall and the wedge support wall, wherein the conductorcontact wall, wedge support wall and rear wall form a wedge receivingchannel; an interface movably coupled to the frame by a connectingmember; and a wedge assembly having a wedge and a fastener, the wedgehaving a body shaped to fit within the wedge receiving channel of theframe and a fastener holder extending from the body, the fastener holderbeing aligned with the mounting member so that the fastener can passthrough the fastener holder into engagement with the mounting member. 2.The electrical power connector assembly according to claim 1, whereinthe connecting member comprises a flexible member having a base, a leghaving one end attached to the base and a second end positioned awayfrom the base, the second end of the leg having an interface couplingmember attached thereto.
 3. The electrical power connector assemblyaccording to claim 2, wherein the flexible member comprises anelastomeric member.
 4. The electrical power connector assembly accordingto claim 2, wherein the base has a substantially arcuate shape.
 5. Theelectrical power connector assembly according to claim 1, wherein therear wall of the frame includes at least one opening configured topermit a portion of the connecting member to pass through the openinginto the wedge receiving channel.
 6. The electrical power connectorassembly according to claim 1, wherein the interface includes a firstside wall and second side wall, wherein the first side wall includes atleast one lead-in, and wherein the second side wall includes a mountingelement used to couple the interface to the connecting member.
 7. Theelectrical power connector assembly according to claim 6, wherein themounting element comprises a channel.
 8. The electrical power connectorassembly according to claim 1, wherein the interface includes a firstcontact surface facing the conductor contact wall and a second contactsurface facing the wedge.
 9. The electrical power connector assemblyaccording to claim 1, wherein the fastener comprises a multi-leadthreading.
 10. The electrical power connector assembly according toclaim 9, wherein the multi-lead threading comprises a triple-leadthreading.
 11. The electrical power connector assembly according toclaim 9, wherein the multi-lead threading comprises a double-leadthreading.
 12. A wedge type electrical power connector assemblycomprising: a frame having a conductor contact wall, a wedge supportwall, a rear wall and a mounting member, the rear wall being between theconductor contact wall and the wedge support wall, wherein the conductorcontact wall, wedge support wall and rear wall form a wedge receivingchannel; an interface positioned within the wedge receiving channel andcoupled to the frame by at least one connecting member; and a wedgeassembly having a wedge and a fastener, the wedge having a wedge-shapedbody that fits within the wedge receiving channel of the frame and afastener holder extending from the body, the body of the wedge having acontact surface facing the conductor contact wall, the fastener holderbeing aligned with the mounting member so that the fastener can passthrough the fastener holder into engagement with the mounting member tomove the wedge between an open position and a clamping position.
 13. Theelectrical power connector assembly according to claim 12, wherein theat least one connecting member comprises a flexible member having abase, a leg having one end attached to the base and a second endpositioned away from the base, the second end of the leg having aninterface coupling member attached thereto.
 14. The electrical powerconnector assembly according to claim 13, wherein the flexible membercomprises an elastomeric member.
 15. The electrical power connectorassembly according to claim 13, wherein the base has a substantiallyarcuate shape.
 16. The electrical power connector assembly according toclaim 13, wherein the rear wall of the frame includes at least oneopening configured to permit a portion of the connecting member to passthrough the opening into the wedge receiving channel.
 17. The electricalpower connector assembly according to claim 12, wherein the interfaceincludes a first side wall and second side wall, wherein the first sidewall includes at least one lead-in, and wherein the second side wallincludes a mounting element used to couple the interface to theconnecting member.
 18. The electrical power connector assembly accordingto claim 17, wherein the mounting element comprises a channel.
 19. Theelectrical power connector assembly according to claim 12, wherein theinterface includes a first contact surface facing the conductor contactwall and a second contact surface facing the wedge.
 20. The electricalpower connector assembly according to claim 12, wherein the fastenercomprises a multi-lead threading.
 21. The electrical power connectorassembly according to claim 20, wherein the multi-lead threadingcomprises a triple-lead threading.
 22. The electrical power connectorassembly according to claim 20, wherein the multi-lead threadingcomprises a double-lead threading.
 23. A wedge type electrical powerconnector assembly comprising: a frame having a conductor contact wall,a wedge support wall, a rear wall and a mounting member, the rear wallbeing between the conductor contact wall and the wedge support wall andincluding at least one opening, wherein the conductor contact wall,wedge support wall and rear wall form a wedge receiving channel; aninterface positioned within the wedge receiving channel and coupled tothe frame by at least one flexible member having a base, a leg havingone end attached to the base and a second end positioned away from thebase, the second end of the leg having an interface coupling memberattached thereto and configured to pass through the at least one openingin the rear wall; and a wedge assembly having a wedge and a fastener,the wedge having a wedge-shaped body that fits within the wedgereceiving channel of the frame and a fastener holder extending from thebody, the body of the wedge having a contact surface facing theconductor contact wall, the fastener holder being aligned with themounting member so that the fastener can pass through the fastenerholder into engagement with the mounting member to move the wedgebetween an open position and a clamping position.
 24. The electricalpower connector assembly according to claim 23, wherein the flexiblemember comprises an elastomeric member.
 25. The electrical powerconnector assembly according to claim 23, wherein the base has asubstantially arcuate shape.
 26. The electrical power connector assemblyaccording to claim 23, wherein the interface includes a first side walland second side wall, wherein the first side wall includes at least onelead-in, and wherein the second side wall includes a mounting elementused to couple the interface to the connecting member.
 27. Theelectrical power connector assembly according to claim 23, wherein themounting element comprises a channel.
 28. The electrical power connectorassembly according to claim 23, wherein the interface includes a firstcontact surface facing the conductor contact wall and a second contactsurface facing the wedge.
 29. The electrical power connector assemblyaccording to claim 23, wherein the fastener comprises a multi-leadthreading.
 30. The electrical power connector assembly according toclaim 29, wherein the multi-lead threading comprises a triple-leadthreading.
 31. The electrical power connector assembly according toclaim 29, wherein the multi-lead threading comprises a double-leadthreading.